Casting Engineer – Automotive Manufacturing

We’re ALTEN Technology USA, an engineering company that provides solutions for engineering, technology, and product development projects. For decades, we’ve been helping our clients develop products that are changing the world, whether that’s by shaping the future of space exploration, saving lives with medical devices that set a new standard of care, or creating the fully autonomous electric taxi of tomorrow. Our team of more than 600 people works across industries including aerospace, medical devices and life sciences, unmanned systems and robotics, automotive OEM and tier 1 suppliers, commercial vehicle, electric vehicles, rail, and more. Our offices across the US have different industry focuses and engage with our clients in different ways, ranging from working on-site at client facilities to performing product development at our delivery centers.

ALTEN Group, our parent company, has been a leader in engineering and information technology for more than 30 years. ALTEN Group operates in 30 countries across Europe, North America, Asia, Africa and the Middle East and employs more than 36,000 people, 88% of whom are engineers. The company covers the whole development cycle and offers a choice of service levels, from technology consulting to complete project outsourcing.

When you join ALTEN Technology USA, you join a group of people passionate about collaborating to solve some of the world’s most technical engineering challenges. Our success is tied to taking care of our employees by building relationships and providing opportunities for mentorship and career growth. We offer comprehensive benefits for all full-time employees, including medical, dental, and vision insurance; a 401(k) plan with employer matching; paid time off (PTO); paid parental leave; and mentorship to help you take your career to the next level. You don’t have to take our word for it that we are a great place to work—we were named on the 2023 Top Workplaces list thanks to feedback from our proud employees.

For a quicker response, send your resume to Leo.Stephen@alten.com or apply directly on LinkedIn! 🚀

Multiple Opening !!

Job Description :

The Casting Engineer is responsible for overseeing the design, development, validation, and optimization of casting processes in automotive manufacturing. This role involves product launch support, PPAP (Production Part Approval Process), PFMEA (Process Failure Mode and Effects Analysis), tooling development, and defect reduction. The engineer will work closely with cross-functional teams, suppliers, and manufacturing plants to ensure high-quality high-pressure die casting (HPDC) and gravity casting processes.

Key Responsibilities:

• Lead the design, development, and validation of casting processes for aluminum and magnesium components.
• Support new product launches, ensuring alignment with PPAP, PFMEA, and APQP requirements.
• Develop and optimize die casting tooling, gating systems, and process parameters.
• Oversee supplier validation, process audits, and quality assessments for cast components.
• Conduct root cause analysis and implement solutions for casting defects such as porosity, shrinkage, and inclusions.
• Collaborate with suppliers, foundries, and internal teams to ensure casting feasibility and manufacturability.
• Manage cost estimation, material selection, and process control for casting projects.
• Implement continuous improvement initiatives to enhance casting quality, production efficiency, and scrap reduction.
• Ensure compliance with automotive industry standards (IATF 16949, GD&T, and ISO requirements).
• Work with simulation tools (MAGMASOFT, ProCAST, or similar) to optimize casting designs and processes.

Requirements:

• Bachelor’s degree in Mechanical Engineering, Metallurgical Engineering, or related field.
• 5 years of experience in casting engineering, die design, and process optimization in an automotive manufacturing environment.
• Strong understanding of HPDC, LPDC, and gravity casting processes.
• Experience with PPAP, PFMEA, APQP, and GD&T.
• Knowledge of casting defect analysis and corrective actions.
• Proficiency in CAD software (CATIA, AutoCAD, or SolidWorks) and casting simulation tools (MAGMASOFT, ProCAST, or FLOW-3D).
• Strong problem-solving, analytical, and project management skills.
• Ability to travel 20-40% as needed.

ALTEN Technology is an Equal Opportunity Employer. Our Policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of an individual’s age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity/expression or veteran status.

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